1 … 101 … 10

Control unit for system leakage tests

Type VPM-VC(Valve Check)

8.22

DescriptionThe VPM-VC valve test module checks the tightness of burner gas shut-off valves in combination with one or two pressure switches. The test is performed in accordance with EN 1643.The program sequence, filling and venting parameters as well as pro-gram times can be adjusted by the user according to the system require-ments.

ApplicationThe VPM-VC has been designed for automatic leak testing between two solenoid valves in gas-consuming devices, either prior to start-up or after switching off the system. The test system can be used as a single leakage tester or in combination with

automatic burners. It is used in gas burner systems for heating, process heating, process industry and gas engines.

ApprovalsEC type testing certificate as per: • EC-Gas Appliances Regulation• EC-Pressure Equipment Directive

The VPM meets the requirements of:- Machinery Directive 2006/42/EC- Low Voltage Directive 2006/95/EC- EMV 2004/108/EC

Approvals in other important gas-consuming countries.CSA approval on requestFM Approvals Class 7610

VPM VC

V1 V2

LGV(NO)

Pp

GW 1

VPM VC

V1

Pp

V3 V2

GW 1

V4

Prin

ted

in G

erm

any

• Edi

tion

01.1

8 • N

r. 26

0 25

7

3 … 102 … 10

VPM-VC Control unit for system leakage tests according to En 1643. Checks tightness of the gas burner shut-off valves either before burner start or after shutdown. Equipment: one or two gas pressure switches. Additional pilot valves are required depending on the system Pressure switches/valves/pilot valves are not part of the scope of delivery!

Technical dataRated voltage (depending on the model)

~ (AC) 230 V +10 % / -15 % 50-60 Hz ±5 %~ (AC) 115 V +10 % / -15 % 50-60 Hz ±5 %

Power consumption max. 10 WPower consumptionTypical

115 V: standby 2.6 W operation 4.6 W230 V: standby 3.1 W operation 5.4 W

Backup fuse L1 6.3 A T (10 A F), integrated, replaceableHumidity DIN 60730-1, no dewing admissibleType of protection IP 42 Ambient temperature -20 °C to +60 °CStorage temperature -40 °C to +80 °CSwitch-on duration 100 % Operational altitude Suitable for use up to 2000 metres above sea levelTest volume UnlimitedMedium Any; gas type depending on pressure switch and valveInlet pressure Any; depending on pressure switch and valveMultifunction output (MFA) Number of operating cycles V1 > 100.000

(terminal 19 + 20, potential-free).Further settings possible via VisionBox + parameter change:1. Freely selectable number of operating cycles up to 6.5 million (standard

100,000) 2. Signal output with freely selectable number of operating cycles of V2,

LGV or release3. Signal output while the test is running or while voltage is applied4. Signal after successful switch-off

Program sequence can be selected Three different program sequences can be selected via DIP switches:1. Valve test before burner start2. Valve test after burner switch-off3. Test sequence with optimised valve operating cycles after burner switch-

off without additional switching cycles. In this case, only one valve will be tested at a time after successful switch-off, --> lower power consumption and increased valve life.

Test times can be set DIP switches can be used to select predefined test times of V1 and V2, enabling optimal setting in case of different test volumes, inlet pressures and leakage rates. Alternatively, individual test times, even different times for V1 and V2, can be set via VisionBox.

Filling and venting attempts Depending on the test volume, different combinations can be selected using DIP switches.

Signalling for V1 and V2 Red/green LEDs signal various information on the program and release states or error codes.

TWI interface Plug-in connection for DUNGS VisionBox. The VisionBox can be used to access the VPM via a PC. The VisionBox is hardware and software for VPM parameter setting. Status information and error error memory data can be read out.

Mounting position As desired

3 … 102 … 10

Application informationEN 676: 2008-11 ... requests tightness checks at burner capacities above 1,200 kW

or already at capacities from 70 kW for burners without pre-purging.EN 746-2: 2011-02 …requests the use of a VPM for some applications. Pre-venting

of the burner chamber can be omitted when using a VPM. Venting of the furnace is done to the atmosphere.

EN 1643: 2001-02 …in combination with a VPM, venting may be done into the furnace for max. 3 s.

Wiring scheme Outputs Electrical data

The sum of the currents of all safety-related consumers must not exceed 5 A!The sum of the currents of all consumers must not exceed 6.3 A (10 A).

11

Release 115/230 VAC / 5 A cos ϕ = 1Minimum load 0.5 W

6 V1 115/230 VAC / 2 A cos ϕ = 1Minimum load 0.5 W

8 V2 115/230 VAC / 2 A cos ϕ = 1Minimum load 0.5 W

10 LGV 115/230 VAC / 2 A cos ϕ = 1Minimum load 0.5 W

1617

External fault

115/230 VAC / 1 A cos ϕ = 1

1920

MFA 115/230 VAC / 1 A cos ϕ = 1

Inputs Electrical data

4 TR Test request

115/230 VAC

13 Pp1 115/230 VAC (NO)

14 Pp2 115/230 VAC (NC)

12 Remote unlocking

115/230 VAC

7 V1_In 115/230 VAC9 V2_In 115/230 VAC

5 … 104 … 10

Signalling unit Error information

V2 V1

Detailed error information via flash codes

All LEDs are flashing:

• when a key press is requested during a level change

• when the VPM is ready for extended unlocking

MFT (RESET) = multifunction switch:

Unlocking switch for error status…max. 5x/15 min.

Changeover switch to switch to the password-protected function level for service and OEM parameter setting via TWI interface by means of the VisionBox.

V2two LEDs green / red

V1two LEDs green / red

Off Constantly red V1 leaking Constantly red Off V2 leakingRed flashing 1x Red flashing 1x Venting errorRed flashing 2x Red flashing 2x Filling error

Switch-on (mains): All LEDs light up as a functional test for approx. 1.5 s.

Waiting for test request:Green LED's flashing slowly (4 s off, 0,125 s on).Depending on the states, the LED-V1 and LED-V2 indicators are flashing or lit constantly

Red flashing 3x Red flashing 3x Wrong position of DIP switch

Red flashing 4x Red flashing 4x Unlockfailed

Red flashing 5x Red flashing 5x Power at V1.In or V2.In before test sequence completed

Constantly red Constantly red ...all other errorsConstantly green

Constantly green

Release signal

RESET V1V2

5 … 104 … 10

A Test sequence B ttest V1, V2 test time C Number of venting or filling attempts

1100

Test during the start phase before burner ignition

1100 10 s 1100 Venting 10 (�)Filling 1

0110 22 s 0110 Venting 1Filling 1

1001 30 s 1001 Venting 1Filling 10

1001 Test after regular shutdown

0011 55 s The following can be changed via the software: P22 for test time V1 P23 for test time V2If this switch position is used, parameter set-ting should be checked via the VisionBox.

0011 Venting 3 (�)Filling 3 (�)The following can be changed via the software: P32: Number of vent-ing operationsP31: Number of filling operationsIf this switch position is used, parameter set-ting should be checked via the VisionBox.

0011 Test after regular shut-down in reduced mode without additional operating cycles

Operating mode "T- Down optimised“: after regular switch-off,one valve is tested at a time alternatively,the other valve is kept open. The alternation takes place during release, when remov-ing the test request next time.

- burner with frequent starts

- longer valve life- reduced power con-

sumption

ttest For the calculation of the test times, see p. 7

Setting must be higher than the calculated time.t DIP > ttest V1 , ttest V2

� For more detailed ex-planations, see instal-lation examples in the VPM-VC operating and mounting instructions.

According to EN1643, 1 filling or 1 empty-ing attempt for max. 3 s into the burner chamber is admissible (DUNGS as-delivered configuration). At filling and emptying times of 1 s of the gas main valves, max. 3 attempts are admissible.If the number of vent-ing attempts is higher, venting must be into a safe area (LGV vent valve).

Modification of the program sequence by an application-specific setting of the B/C DIP switches

A B C

0000 0000 0000AAAA BBBB CCCC

7 … 106 … 10

Please note: Switch positions � � � �

�

According to EN1643, 1 filling or 1 emptying attempt for max. 3 s into the burner chamber is admissible (DUNGS as-delivered con-figuration). At filling and emptying times of 1 s of the gas main valves, max. 3 attempts are admis-sible.

�

When filling or emptying attempts are carried out via pilot valves, the situation described in �, shows that the specifications of EN1643 are also met with 10 filling or emptying attempts if pilot valves are used that can reach at most only 1/10 of the maximum gas flow of the main valves.

�

If the valve check is carried after a regu-lar shutdown, the system setup must ensure that locking the system prevents a valve check during a fault situation. This can only be achieved by safe interruption of the power supply to the VPM when a fault occurs.

�

If this switch position is used, parameter setting should be checked via the VisionBox.

1a Direct valve check via LGV, venting through roofValve check system component: VPM-VC, Pp, LGV- - -

VPM VC

V1 V2

LGV(NO)

Pp

GW 1

NO

NC

Pp1 Pp2

TR

L1

V1V2

V1

in

LGV

OK

FAU

LT

RE

MO

TE R

ES

ET

VPM-VC1 a + 1b

Direkte Ventilkontrolle mit LGV

FA

FAU

LT

CO

M M

ULT

I

MU

LTI

CO

M

NO

NC

N

Pp1

GW1

N

DIP-mode:A: 1100 1001 � 0011 � �

B: xxxxC: 1100 0110 0011 � �

Parameter:---

1b Direct valve check via LGV, venting into the burner chamberValve check system component: VPM-VC, Pp, LGV- - -

VPM VC

V1 V2

Pp

GW 1

LGV(NO)

NO

NC

Pp1 Pp2

TR

L1

V1V2

V1

in

LGV

OK

FAU

LT

RE

MO

TE R

ES

ET

VPM-VC1 a + 1b

Direkte Ventilkontrolle mit LGV

FA

FAU

LT

CO

M M

ULT

I

MU

LTI

CO

M

NO

NC

N

Pp1

GW1

N

DIP-mode:A: 1100 1001 � 0011 � �

B: xxxxC: 1100 � 0110 0011 � �

Parameter:---

Installation examplesThe functional principle must be selected in accordance with the local regulations

Prevent soiling by using appropriate gas filters

Use of pilot valves recommended

Notes regarding 1a, 1b, 2:If a valve closed when not powered is replaced instead of a LGV (open when not powered), it must be connected to output V2 (terminal 8).

7 … 106 … 10

2 Valve check via pilot valves V3, LGV venting through the roofValve check system component: VPM-VC, Pp, V3, LGV- - -

VPM VC

V1

Pp

V3

GW 1 V2

LGV(NO)

NO

NC

Pp1 Pp2

TR

L1

V3 LGV

OK

FAU

LT

RE

MO

TE R

ES

ET

VPM-VC2 Ventilkontrolle mit Hilfsventilen V3,LGV

FA

FAU

LT

CO

M M

ULT

I

MU

LTI

CO

M

NO

NC

N

Pp1

GW1

V1

N

V2

N

DIP mode:A: 1100 1001 � 0011 � �

B: xxxxC: 1100 0110 1001 � 0011 � �

Parameter:---

3 Direct valve checkValve check system component: VPM-VC, Pp- - -

VPM VC

V1 V2

Pp

GW 1

NO

NC

Pp1 Pp2

TR

L1

V1 V2

OK

FAU

LT

RE

MO

TE R

ES

ET

VPM-VC3

DirekteVentilkontrolle

FA

FAU

LT

CO

M M

ULT

I

MU

LTI

CO

M

NO

NC

N

Pp1

GW1

V1

in

V2

in

DIP mode:A: 1100 1001 � 0011 � �

B: xxxxC: 0110 0011 �, �Parameter:---

4 Direct valve check via pilot valves, venting into the burner chamber- - - Valve check system component: VPM-VC, Pp, V3, V2

VPM VC

V1

Pp

V3 V2

GW 1

V4

NO

NC

Pp1 Pp2

TR

L1

v3 V2

OK

FAU

LT

RE

MO

TE R

ES

ET

VPM-VC4

Ventilkontrolle

FA

FAU

LT

CO

M M

ULT

I

MU

LTI

CO

M

NO

NC

N

Pp1

GW1

V1

N

V4

N

DIP mode:A: 1100 1001 � 0011 � �

B: xxxxC: 1100 � 0110 1001 0011 �, �Parameter: ---

9 … 108 … 10

5a Valve check via pilot valves, venting to V2 via LGVtype2 (normally closed)Valve check system component: VPM-VC, Pp, LGVType2 (NC)- - -

The LGV type 2 is required for opening the gas flow behind V2 (to the burner chamber or atmosphere), al-lowing it to be emptied when V2 is deliberately (during the test) open. The pressure behind V2 must be able to escape, since otherwise V2, as response to "No gas pressure", allows gas to pass in the reverse direction during the test time, if there is still pressure behind V2. This allows the pressure to drop in the monitored inter-space if V2 is leaking. During release (automatic burner control is working), the LGV type 2 is closed.

VPM VC

V1 V2

Pp

GW 1

LGVTyp 2(NC)

NO

NC

Pp1 Pp2

TR

L1

v1

OK

FAU

LT

RE

MO

TE R

ES

ET

VPM-VC5a + 5bVentilkontrolle mit Hilfsventilen, Entlüftung nach V2 über LGVTyp2 (Normaly close)

FA

FAU

LT

CO

M M

ULT

I

MU

LTI

CO

M

NO

NC

N

Pp1

GW1

V1

in

V2

in

LGV

Typ2

v2

Das LGV-Typ2 wird benötigt um den Gasweg hinter V2 zu öffnen (zum Brennraum oder Atmosphäre), damit kann einerseits entleert werden wenn V2 bewusst (während der Prüfung) offen ist. Der Druckhinter V2 muss entweichen können da sonst V2 während der Prüfzeit auf „kein Gasdruck“ Gas in Rückrichtung durchlässt falls hinter V2 noch Druck besteht.Andererseits kann der Druck im überwachten Zwischenraum bei undichtem V2 abfallen. Während der Freigabe (Feuerungsautomat arbeitet) ist das LGV-Typ2 geschlossen.

DIP mode:A: 1100 1001 � 0011 � �

B: xxxxC: 1100 0110 0011 � �

Parameter:P12 = 1

5b Valve check via pilot valves, venting to V2 via LGVtype2 (normally closed)into the burner chamberValve check system component: VPM-VC, Pp, LGVType 2 (NC)- - -

The LGV type2 is required for opening the gas flow behind V2 (to the burner chamber or atmosphere). This allows the pressure to drop in the monitored interspace if V2 is leaking. Emptying takes place via LGV.During release (automatic burner control is working), the LGV and the LGV-type 2 are closed.

VPM VC

V1 V2

Pp

GW 1

LGVTyp 2(NC)

NO

NC

Pp1 Pp2

TR

L1

v1

OK

FAU

LT

RE

MO

TE R

ES

ET

VPM-VC5a + 5bVentilkontrolle mit Hilfsventilen, Entlüftung nach V2 über LGVTyp2 (Normaly close)

FA

FAU

LT

CO

M M

ULT

I

MU

LTI

CO

M

NO

NC

N

Pp1

GW1

V1

in

V2

in

LGV

Typ2

v2

Das LGV-Typ2 wird benötigt um den Gasweg hinter V2 zu öffnen (zum Brennraum oder Atmosphäre), damit kann einerseits entleert werden wenn V2 bewusst (während der Prüfung) offen ist. Der Druckhinter V2 muss entweichen können da sonst V2 während der Prüfzeit auf „kein Gasdruck“ Gas in Rückrichtung durchlässt falls hinter V2 noch Druck besteht.Andererseits kann der Druck im überwachten Zwischenraum bei undichtem V2 abfallen. Während der Freigabe (Feuerungsautomat arbeitet) ist das LGV-Typ2 geschlossen.

DIP mode:A: 1100 1001 � 0011 � �

B: xxxxC: 1100 0110 0011 � �

Parameter:P12 = 1

9 … 108 … 10

6a Valve check via pilot valves and LGV, venting to V2 via LGVtype2 (normally closed)Venting through roofValve check system component: VPM-VC, Pp, LGV, LGVtype2 (NC)

- - -

VPM VC

V1 V2

Pp

GW 1

LGVTyp 2(NC)

LGV(NO)

NO

NC

Pp1 Pp2

TR

L1

v1 LGV Typ2

OK

FAU

LT

RE

MO

TE R

ES

ET

VPM-VC6a + 6b Ventilkontrolle mit Hilfsventilen und LGV, Entlüftung nach V2 über LGVTyp2 (Normaly close)

FA

FAU

LT

CO

M M

ULT

I

MU

LTI

CO

M

NO

NC

N

Pp1

GW1

V2

N

V1

in

LGV

Das LGV Typ2 wird benötigt um den Gasweg hinter V2 zu öffnen (zum Brennraum oder Atmosphäre). Dadurch kann der Druck im überwachten Zwischenraum bei undichtem V2 abfallen. Entleert wirdüber LGV.Während der Freigabe (Feuerungsautomat arbeitet) ist das LGV und das LGV-Typ2 geschlossen.

DIP mode:A: 1100 1001 � 0011 � �

B: xxxxC: 1100 0110 0011 � �

Parameter:P11 = 1

6b Valve check via pilot valves and LGV, venting to V2 via LGVtype2 (normally closed)Valve check system component: VPM-VC, Pp, LGV, LGVtype2 (NC)- - -

VPM VC

V1 V2

Pp

GW 1

LGVTyp 2(NC)

LGV(NO)

NO

NC

Pp1 Pp2

TR

L1

v1 LGV Typ2

OK

FAU

LT

RE

MO

TE R

ES

ET

VPM-VC6a + 6b Ventilkontrolle mit Hilfsventilen und LGV, Entlüftung nach V2 über LGVTyp2 (Normaly close)

FA

FAU

LT

CO

M M

ULT

I

MU

LTI

CO

M

NO

NC

N

Pp1

GW1

V2

N

V1

in

LGV

Das LGV Typ2 wird benötigt um den Gasweg hinter V2 zu öffnen (zum Brennraum oder Atmosphäre). Dadurch kann der Druck im überwachten Zwischenraum bei undichtem V2 abfallen. Entleert wirdüber LGV.Während der Freigabe (Feuerungsautomat arbeitet) ist das LGV und das LGV-Typ2 geschlossen.

DIP mode:A: 1100 1001 � 0011 �B: xxxxC: 1100 � 0110 0011 � �

Parameter: P11 = 1

10 … 1010 … 10

Subject to technical modification in the interest of technical progress.

Control unit for system leakage tests

Type VPM-VC(Valve Check)

Company addressKarl Dungs GmbH & Co. KGKarl-Dungs-Platz 1D-73660 Urbach, GermanyPhone +49 (0)7181-804-0Fax +49 (0)7181-804-166

Postal addressKarl Dungs GmbH & Co. KGPostfach 12 29D-73602 Schorndorf, Germanye-mail: info@dungs.comInternet: www.dungs.com

Dimensions Installation

150

77

2 x ø for PG 9

6 x ø for M16 x 1.5

AccessoriesGas pressure switch Depending on the operating pressure, see data sheetsLGW...A4 (5.08)GW...A6 (5.01)GW...A4 HP (5.04)Pilot solenoid valvessee data sheets DMV... (7.30, 7.37, 7.38), MV 502 (6.21)MVD ... (6.20)MPA VisionBoxAs addition to MPA parameterisation and service box for setting VPM parameters via a PC/laptop.

Hat rail mountingMounting rail 35 mm

Mounting bores ø 4.5Screw ø 4

100

38,5

ø 4,

5

Version Description Order No.Complete device VPM-VC cpl. 230 VAC 259 696

VPM-VC cpl. 115 VAC 259 697

Top part VPM-VC 230 VAC 258 625

VPM-VC 115 VAC 258 890

Base 1 piece 259 694

48 piece 259 695

152.5